The additional details needed for this cover are two notches to provide clearance for a fuel hose and supercharger intercooler coolant pipe. I marked and cut out openings and then verified the notched areas would provide adequate clearance.
Filler pieces are cut, formed to fit, and then welded in place. I used TIG with very proud beads on top and bottom surfaces to ensure there would be plenty of metal for a nice edge.
The two notches cleaned up nice after filing and metal finishing.
I then dressed out the welds on the remaining 3 corners and here’s the finished cover.
A final test fit to ensure it still fits well.
Here’s before…
… and after pictures with the new engine covers in place.
It’s amazing how a little bit for shaped sheet aluminum can really clean up a bunch of ugly bits on the top of an engine